Rockwell Automation: DCS Platform Migration, Pulp & Paper Industry

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PUBLIC INFORMATION

CS17: Multiple Concurrent Legacy Migrations Achieved with a PlantPAx® DCS Platform


Agenda

Benefits

Project Details

Solution Selection Criteria

Project Challenge

Company Profile

Next Steps

Q/A


Company ProfileBackground

Founded in 1996 Employ over 40 Process Control Engineers & E/I Technicians Control System Services - Design, build, configure, test, install, checkout and startup, of

control system hardware and software. Operational IT Services - Design, build, configure, and install of network and data center

systems. Data Historian Services - Historian configuration, installation, reporting, and data

visualization. Cyber Security Services - Risk assessment, network analysis, system design, installation

and support. 24/7 Monitoring and maintenance support services for all areas of industrial control

system platforms.


Company ProfileBackground

Over two decades of expertise in the following industries: Pulp & Paper Specialty Chemicals Food & Beverage Life Science Municipal Utilities

Platform independent solutions with experience in a majority of legacy and current technology offerings.

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Agenda

Benefits

Project Details

Solution Selection Criteria

Project Challenge

Company Profile

Next Steps

Q/A


Project ChallengeProject Overview

Paper Industry End User Customer Conversion of multiple legacy DCS platforms and PLC/5 Hardware Two major automation platform upgrades during project lifecycle

Recovery Boiler Paper Machine

Project Constraints Recovery

Project execution period during facility annual outage, lasting 6 days. Paper Machine

Major machine redesign / rebuild concurrently executed with DCS platform upgrade Common utility systems used in areas outside of machine rebuild Staged commissioning and trial runs for operations


Project ChallengeDCS Replacement Driving Factors

Technical Factors Spare parts unavailability Diminishing technical knowledge of multiple platforms in both areas Desire to leverage HART data from capable transmitters

Business Factors Cost of mature technology Reduced life-cycle costs Increase business intelligence Major capital investment in reconfiguration of facility


Project ChallengeExisting Platforms

Paper Machine DCS System – ABB 800xA

14 x ABB MOD300 SC Controllers 2 x ABB 800xA PM866 Controllers 2,350 I/O (TRIO & S800)

PLC System – AB 2 x AB PLC/5 Controllers 5 x 1771 I/O racks

HMI - 800xA (Process Portal A) QCS System – ABB

Recovery Boiler DCS System - Siemens APACS

1 x ACMx APACS Controller 375 APACS I/O

PLC System - AB 1 x AB PLC/5 Controller HMI - Proficy iFIX 4.0 10 x 1771 I/O racks


Project ChallengeDelivered Platforms

Paper Machine System 2 redundant PASS system server applications 29 x Operator Clients (mixture of physical and virtual) FactoryTalk Historian, VantagePoint, & AssetCentre 6 x 1756-L75 PACs 19 x 1756 (ControlLogix) I/O racks via Ethernet DLR 2 x 1734 (PointIO) I/O racks via Ethernet DLR 5 x 1771 (PLC5) I/O racks via DHRIO

Integration of ABB ACS800 VF Drives via Ethernet Integration of Rockwell E300 Overload Relays via REP Protocol

Ring Quality Control System from Valmet consisting of:

1 new dry end scanner 1 new single point wet end scanner Integration to Rockwell via Ethernet I/P

Recovery Boiler System 1 redundant PASS system server application 8 x Operator Clients (mixture of physical and virtual) FactoryTalk Historian FactoryTalk VantagePoint FactoryTalk AssetCentre 1 x 1756-L75 PAC w/ Redundancy 4 x 1756 (ControlLogix) I/O racks via Ethernet DLR 2 x 1794 (Flex) I/O racks via Ethernet DLR 10 x 1771 (PLC5) I/O racks via DHRIO

Integration of ABB ACS800 VF Drives via Ethernet Integration of 5KV Powerflex 7000 VF Drive via Ethernet Integration of second recovery boiler controls into HMI layer

1 x ACMx APACS Controller 1 x AB PLC/5 Controller


Thank You!

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Engineering

Rockwell Automation: DCS Platform Migration, Pulp & Paper Industry